Echotel

Model 910

Installation and Operating Manual

Ultrasonic
Level
Switch
Read this Manual Before Installing
This manual provides information on the Echotel Model
910 Ultrasonic Liquid Level Switches. It is important that
all instructions are read carefully and followed in
sequence. Detailed instructions are included in the
Installation section of this manual.
Conventions Used in this Manual
Certain conventions are used in this manual to convey
specific types of information. General technical material,
support data, and safety information are presented in
narrative form. The following styles are used for notes,
cautions, and warnings.
NOTES
Notes contain information that augments or clarifies
an operating step. Notes do not normally contain
actions. They follow the procedural steps to which
they refer.
Cautions
Cautions alert the technician to special conditions that
could injure personnel, damage equipment, or reduce
a components mechanical integrity. Cautions are also
used to alert the technician to unsafe practices or the
need for special protective equipment or specific mate-
rials. In this manual, a caution box indicates a poten-
tially hazardous situation which, if not avoided, may
result in minor or moderate injury.
WARNINGS
Warnings identify potentially dangerous situations or
serious hazards. In this manual, a warning indicates an
imminently hazardous situation which, if not avoided,
could result in serious injury or death.
Safety Messages
The Echotel Model 910 is designed for use in Category II,
Pollution Degree 2 installations. Follow all standard
industry procedures for servicing electrical and computer
equipment when working with or around high voltage.
Always shut off the power supply before touching any
components. Although high voltage is not present in this
system, it may be present in other systems.
Electrical components are sensitive to electrostatic
discharge. To prevent equipment damage, observe
safety procedures when working with electrostatic
sensitive components.
This device complies with Part 15 of the FCC rules.
Operation is subject to the following two conditions:
(1) This device may not cause harmful interference,
and (2) This device must accept any interference
received, including interference that may cause unde-
sired operation.
WARNING! Explosion hazard. Do not connect or
disconnect equipment unless power has been switched off
or the area is known to be non-hazardous.
Low Voltage Directive
For use in Category II installations. If equipment is used
in a manner not specified by manufacturer, protection
provided by equipment may be impaired.
Notice of Trademark, Copyright, and Limitations
Magnetrol & Magnetrol logotype and Echotel are regis-
tered trademarks of Magnetrol International.
Copyright 2011 Magnetrol International, Incorporated.
All rights reserved.
Performance specifications are effective with date of issue
and are subject to change without notice. Magnetrol
reserves the right to make changes to the product
described in this manual at any time without notice.
Magnetrol makes no warranty with respect to the accura-
cy of the information in this manual.
Warranty
All Magnetrol Model 910 Level Switches are
warranted free of defects in materials or workmanship for
two full years from the date of original factory
shipment.
If returned within the warranty period; and, upon
factory inspection of the control, the cause of the claim is
determined to be covered under the warranty; then,
Magnetrol will repair or replace the control at
no cost to the purchaser (or owner) other than
transportation.
Magnetrol shall not be liable for misapplication, labor
claims, direct or consequential damage or expense arising
from the installation or use of equipment.
There are no other warranties expressed or implied,
except special written warranties covering some
Magnetrol products.
Quality Assurance
The quality assurance system in place at Magnetrol guar-
antees the highest level of quality throughout the compa-
ny. Magnetrol is committed to providing
full customer satisfaction both in quality products and
quality service.
The Magnetrol quality assurance system
is registered to ISO 9001 affirming its
commitment to known international
quality standards providing the strongest
assurance of product/service quality
available.
51-604 Echotel Model 910
 1.0 Introduction
Echotel Model 910 Level Switches utilize ultrasonic
contact technology for measuring level in clean liquid
applications.

1.1 Principle of Operation

The Model 910 Level Switch uses ultrasonic energy to

detect the presence or absence of liquid in a transducer gap.
The basic principle behind ultrasonic contact technology is
Ultrasonic
transducer
that high-frequency sound waves are easily transmitted
across a transducer gap in the presence of a liquid medium,
but are severely attenuated when the gap is dry. The
Model 910 uses an ultrasonic frequency of 3 MHz to
perform this liquid level measurement in a wide variety of
process media and application conditions.

The transducer uses a pair of piezoelectric crystals that are

Transmit Receive encapsulated in epoxy at the tip of the 316 stainless steel
crystal crystal
transducer. The crystals are made of a ceramic material,
that vibrates at a given frequency when subjected to an
applied voltage. The transmit crystal converts an electrical
signal from the Model 910 electronics into an ultrasonic
signal. When liquid is present in the gap, the receive
crystal is able to sense the ultrasonic signal from the
transmit crystal and convert it back to an electrical signal.
This signal is sent to the electronics to indicate the pres-
Ultrasonic signal transmission ence of liquid in the transducer gap. When there is no
across transducer gap
liquid present, the ultrasonic signal is attenuated, and is
Figure 1 not detected by the receive crystal.

2.0 Installation

2.1 Unpacking

Unpack the instrument carefully. Inspect all units for

damage. Report any concealed damage to carrier within
24 hours. Check the contents of the packing slip and
purchase order. Check and record the serial number for
future reference when ordering parts.

Model # _____________________________________

Serial # _____________________________________

51-604 Echotel Model 910 3

 2.2 Electrostatic Discharge (ESD)
Handling Procedure

Magnetrol electronic instruments are manufactured to the

highest quality standards. These instruments use electronic
components that may be damaged by static electricity
present in most work environments.

The following steps are recommended to reduce the risk of

component failure due to electrostatic discharge.
Ship and store circuit boards in anti-static bags. If an anti-
static bag is not available, wrap the board in aluminum
foil. Do not place boards on foam packing materials.
Use a grounding wrist strap when installing and removing
circuit boards. A grounded workstation is recommended.
Handle circuit boards only by the edges. Do not touch
components or connector pins.
Make sure that all electrical connections are completely
made and none are partial or floating. Ground all equip-
ment to a good, earth ground.

2.3 Preliminary Operational Check

After unpacking and before installation, perform the

following operational check on the unit in a non-
hazardous area:
1. Apply proper operating voltage to terminals L1 and L2/N.
Power supply ground should be connected to the green
ground screw in housing base.
2. Fill a suitable container with liquid.
3. Place transducer gap in the liquid. The relay output should
actuate.
4. Remove transducer from the liquid. The relay output
should de-actuate. In case of malfunction, consult
Section 3.1, Troubleshooting on page 8.
Caution: This unit contains CMOS electronics which may become
damaged by static electricity. Do not touch any semicon-
ductor devices unless you are properly grounded.

4 51-604 Echotel Model 910

 2.4 Mounting
Filling line
High alarm Low alarm

Gap must be High alarm

turned vertical

Pump protection

Top View of
Horizontal Mounting
Pump
Low alarm

Figure 2
Conduit Typical Mounting Orientations
connection

Never tighten by Model 910 level switches are shipped as integral units with
turning housing the electronics assembled to the transducer. They may be
3 4 " NPT Use wrench here
mounted in a variety of positions as shown in Figures 2
thread through 5.
Figure 3
Vertical Mounting Proper orientation of the transducer gap will provide
Gap must be
maximum performance in difficult applications. When
turned vertical Install so that the switch is mounted horizontally, the transducer gap
to allow medium wrench flats
are vertical must be turned vertical to allow proper drainage of the
to fall through
liquid media. See Figures 2 and 4.

Screw transducer into the opening using pipe compound

or thread tape. If flanged, bolt unit to mating flange with
proper gasket.
Tank wall Caution: Never tighten unit on the tank connection by turning the
Figure 4 housing. Use a wrench on the transducer mounting nut
Horizontal Mounting flats. Use thread tape or suitable pipe compound on the
threads. Do not overtighten.
Gap must
extend 1" (25 mm) When installed in a nozzle or pipe, the transducer gap
beyond
end of must extend into the tank at least one inch beyond the
nozzle inside tank wall. Refer to Figure 5.

Figure 5
Nozzle Mounting

51-604 Echotel Model 910 5

 2.5 Wiring

2.5.1 Power
Power connections are made at the two-position terminal
block labeled TB1 within the electronics enclosure.
Use of 1422 AWG wire is recommended.
NOTE: Observe all applicable electrical codes and proper wiring
procedures.

1. Make sure the power is turned off.

2. Unscrew and remove the housing cover.
3. Prevent moisture seepage into housing by installing an
approved seal-drain fitting in the conduit run leading to
the unit.
4. Route wires into housing.
5. Connect ground wire to green ground screw located in
the base of the housing. DO NOT proceed until ground
connection is made.
6. After grounding is complete, connect the power leads to
proper terminals as follows:
VAC Units VDC Units
L1, L2/N +,
Caution: In hazardous areas, do not power the unit until the
conduit is sealed and the enclosure cover is screwed
down securely.

7. Dress wiring to ensure no interference or contact with

cover or circuit board components.

TB1 Power Wiring

6 51-604 Echotel Model 910

 2.5.2 Relay
Model 910 switches have a number of possible relay
wiring options. The table below lists the relay contact
positions for all possible combinations of power failure,
condition of the transducer gap, and fail-safe jumper
position. The user must decide which combinations
constitute fail-safe and alarm conditions, and then select
the appropriate relay wiring and fail-safe position.
1. Run relay output wiring to the terminal blocks labeled
TB2 and TB3. Ensure that the load to be controlled is
within the relays rated capacity as shown in Section 3.3.2,
Electrical on page 10.
2. Select high or low fail-safe using the P1 jumper.

P1 Fail-safe Line Transducer Relay Terminals

Jumper Position Power Gap CM to NC CM to NO
Dry Closed Open
On
Wet Open Closed
Low level
Dry Closed Open
Failure
Wet Closed Open
Dry Open Closed
On
Wet Closed Open
High level
Dry Closed Open
Failure
Relay Output Wiring Wet Closed Open

3. Replace housing cover. Installation is complete.

Caution: Never tighten unit to the tank connection by turning the

housing. Use a wrench on the transducer mounting nut
flats. Use thread tape or suitable pipe compound on
P1
threads. Do not overtighten.

P1
LL HL

P1 Fail-safe Jumper

51-604 Echotel Model 910 7

3.0 Reference Information

3.1 Troubleshooting
Caution: In hazardous areas, do not remove housing cover until power is disconnected and atmosphere is deter-
mined to be safe.

3.1.1 No signal with level change

a. Verify power and control circuit wiring.
b. Make sure liquid is filling the transducer gap.
c. Check for dense foam on surface or dried product in the gap. Unit will not function properly if
either condition exists.
d. Check transducer phone plugs for proper insertion in J1 and J2.
e. If control circuit does not actuate, consult factory.
3.1.2 Calibration
Model 910 switches do not require field calibration. The set point is not adjustable.
3.1.3 Switch chatter
a. Check voltage to make sure it is within tolerances shown in Section 3.3.2.
b. Check for turbulence. Relocate control or isolate from turbulence.
c. Check for excessive aeration.
d. Consult factory.
3.1.4 Control output will not de-actuate
a. Check transducer for plugged gap.
b. Check for dense foam or liquid in gap.
c. If control circuit does not de-actuate, consult factory.

3.2 Agency Approvals

AGENCY APPROVED MODEL PROTECTION METHOD AREA CLASSIFICATION

FM 910-XXXX-XXX Explosion Proof Class I, Div. 1; Groups B, C & D

Class II, Div. 1; Groups E, F, & G
Class III, NEMA Type 4X, T6
910-XXXX-XXX Non-Incendive Class I, Div. 2; Groups A, B, C, & D
Class II, Div. 2; Groups F & G
Class III, NEMA Type 4X, T5
CSA 910-XXXX-XXX Explosion Proof Class I, Div. 1; Groups C & D
Class II, Div. 1; Group E, F, & G
Class III, Type 4X, T6
910-XXXX-XXX Non-Incendive Class I, Div. 2; Groups A, B, C, & D
Class II, Div. 2; Groups E, F, & G
Class III, Type 4X, T5
ATEX 910-5XXX-XXX II 1/2 G EEx d II C T6/EEx e II T6
910-PXXX-XXX

Note: Consult factory for Brazilian INMETRO BR-Ex d IIC T6 IP66 approval. These units have been tested to EN 50081-2
and EN 50082-2 and are in compliance with
the EMC Directive 89/336/EEC.

8 51-604 Echotel Model 910

3.3 Specifications
3.3.1 Physical

inches (mm)

4.63 4.63
(117) Dia. (117) Dia.
3.00 Rotation 3.44 (87)
(76) clearance Rotation clearance
3/4"NPT
2.75 2.75
4.48 plugged (70)
(70) 4.48
(113) (113)
6.25 6.25 3/4" NPT
(158) 3/4" NPT (158)
3.50 3.50
Optional (88) Optional (88)
mounting mounting
flange flange
3/4" NPT 3/4" NPT
tank connection Actuation length tank connection Actuation length

Actuation point .25 (6) Actuation point .25 (6)

.875 (22) Dia. .875 (22) Dia.

316 stainless steel housing Aluminum sand cast housing

(Single 34" NPT conduit) (Dual 34" NPT conduits)

4.63
(117) Dia.
3.44 (87) 4.63
Rotation clearance (117) Dia. 3.44 (87)
3/4"NPT Rotation clearance
2.75 3/4" NPT
plugged (70) 2.75
4.48 (plugged)
(113) 4.48 (70)
6.25 (113)
3/4" NPT
(158) 3/4" NPT

.25 (6)
1" BSP Actuation length
process connection Actuation length

Actuation point .25 (6) Actuation point .25 (6)

.875 (22) Dia. .875 (22) Dia.

Aluminum sand cast housing Aluminum sand cast housing

(Dual 34" NPT conduit w/1" BSP process connection) (Dual 34" NPT conduit with hygienic flange)

 1" (Code 001) minimum with NPT threaded process connections.

2" (Code 002) minimum with hygienic or ANSI flanged process connections.

 25 (Code 003) mm minimum with NPT threaded process connections.

50 (Code 005) mm minimum with 1" BSP, and hygienic or ANSI flanged process connections.

51-604 Echotel Model 910 9

 3.3.2 Electrical

Power Supply: 120 VAC (+10%/-15%), 50/60 Hz

240 VAC (+10%/-15%), 50/60 Hz
24 VDC (10%)
Power Consumption: 2.5 VA nominal
Relay Output: Gold flash DPDT relay: 10 amps @ 120 VAC, 240 VAC, 24 VDC 
Hermetically sealed DPDT relay: 5 amps @ 120 VAC, 24 VDC, and
3 amps @ 240 VAC
Repeatability: 0.078" (2 mm)
Fail-safe Configuration: Field selectable high or low
Calibration: None required
Ambient Temperature: Electronics: -40 to +158 F (-40 to +70 C)
Process Temperature: Transducer: -40 to +250 F (-40 to +121 C)
Operating/Non-Operating Pressure: 800/1500 psig (55/103 bar)
Shock ANSI/ISA-S71.03 Class SA1
Vibration ANSI/ISA-S71.03 Class VC2

 Gold flash DPDT relay is rated at 8 amps when used with housing codes 5 or P

3.4 Replacement Parts

No. Description Part Number

120 VAC w/10 amp relay Z30-2043-003
240 VAC w/10 amp relay Z30-2043-004
24 VDC w/10 amp relay Z30-2043-002
1 PC Board
3 120 VAC w/5 amp HS relay Z30-2043-011
1 240 VAC w/3 amp HS relay Z30-2043-012
4
24 VDC w/5 amp HS relay Z30-2043-010
Aluminum w/FM and CSA 004-9182-002
Aluminum w/all 3 approvals 004-9182-008
2 Housing
2 Base 316 SS w/FM and CSA 004-9140-001
316 SS w/CENELEC 004-9140-001
Aluminum w/FM and CSA 004-9105-001
Aluminum w/all 3 approvals 004-9105-005
5 3 Housing
Cover 316 SS w/FM and CSA 004-9142-001
316 SS w/CENELEC 004-9142-001
4 O-Ring 012-2101-345
5 Transducer Consult factory

WARNING! Explosion hazard Substitution of com-

ponents may impair suitability for Class 1,
Division 2 rating.

WARNING! Explosion hazard Do not disconnect

equipment unless power has been switched
off, or the area is known to be non-
hazardous.

10 51-604 Echotel Model 910

3.5 Model Numbers

3.5.1 Model 910

HOUSING
A Aluminum sand cast with 34" NPT dual conduit, FM or CSA approvals
Y 316 stainless steel with 34" NPT single conduit, FM or CSA approvals
P Aluminum sand cast with 34" NPT dual conduit, FM, CSA and ATEX approvals
5 316 stainless steel with 34" NPT single conduit, ATEX approval

TRANSDUCER UNIT OF LENGTH

1 English (actuation length in inches)
M Metric (actuation length in centimeters)

PROCESS CONNECTION
A 3
4" NPT
2 1" NPT
9 1" BSP
3 112" hygienic flange (Compatible with Tri-Clamp fittings)
4 2" hygienic flange (Compatible with Tri-Clamp fittings)
1 1" 150 lb. ANSI raised face flange
C 112" 150 lb. ANSI raised face flange
D 2" 150 lb. ANSI raised face flange
E 1" 300 lb. ANSI raised face flange
F 112" 300 lb. ANSI raised face flange
G 2" 300 lb. ANSI raised face flange

INPUT POWER
0 120 VAC with 10 amp DPDT gold flash relay
1 240 VAC with 10 amp DPDT gold flash relay
2 24 VDC with 10 amp DPDT gold flash relay
H 120 VAC with 5 amp DPDT hermetically sealed relay
J 240 VAC with 3 amp DPDT hermetically sealed relay
K 24 VDC with 5 amp DPDT hermetically sealed relay

ACTUATION LENGTH
1" to 96" in 1" increments (with Transducer Unit of Length
code 1) Example: 4 inches = 004  
3 cm to 244 cm in 1 cm increments (with Transducer Unit
of Length code M) Examples: 6 centimeters = 006  

9 1 0
 1" (code 001) minimum with NPT process connections, 2" (code 002) minimum with hygienic or ANSI flanged process connections.
 2.5 cm (code 003) minimum with NPT process connections, 5 cm (code 005) minimum with 1" BSP, or hygienic or ANSI flanged
process connections.
 Consult factory for longer lengths.

51-604 Echotel Model 910 11

 ASSURED QUALITY & SERVICE COST LESS

Service Policy Return Material Procedure

Owners of Magnetrol may request the return of a control So that we may efficiently process any materials that are
or any part of a control for complete rebuilding or replace- returned, it is essential that a Return Material
ment. They will be rebuilt or replaced promptly. Controls Authorization (RMA) number be obtained from the
returned under our service policy must be returned by factory, prior to the materials return. This is available
Prepaid transportation. Magnetrol will repair or replace through a Magnetrol local representative or by contacting
the control at no cost to the purchaser (or owner) other the factory. Please supply the following information:
than transportation if: 1. Company Name
1. Returned within the warranty period; and 2. Description of Material
2. The factory inspection finds the cause of the claim 3. Serial Number
to be covered under the warranty. 4. Reason for Return
If the trouble is the result of conditions beyond our con- 5. Application
trol; or, is NOT covered by the warranty, there will be Any unit that was used in a process must be properly
charges for labor and the parts required to rebuild or cleaned in accordance with OSHA standards, before it is
replace the equipment. returned to the factory.
In some cases it may be expedient to ship replacement A Material Safety Data Sheet (MSDS) must accompany
parts; or, in extreme cases a complete new control, to material that was used in any media.
replace the original equipment before it is returned. If All shipments returned to the factory must be by prepaid
this is desired, notify the factory of both the model and transportation.
serial numbers of the control to be replaced. In such
cases, credit for the materials returned will be determined All replacements will be shipped F.O.B. factory.
on the basis of the applicability of our warranty. NOTE: See Electrostatic Discharge Handling Procedure
No claims for misapplication, labor, direct or consequen- on page 4.
tial damage will be allowed.

5300 Belmont Road Downers Grove, Illinois 60515-4499 630-969-4000 Fax 630-969-9489 www.magnetrol.com
145 Jardin Drive, Units 1 & 2 Concord, Ontario Canada L4K 1X7 905-738-9600 Fax 905-738-1306
Heikensstraat 6 B 9240 Zele, Belgium 052 45.11.11 Fax 052 45.09.93
Regent Business Ctr., Jubilee Rd. Burgess Hill, Sussex RH15 9TL U.K. 01444-871313 Fax 01444-871317 BULLETIN: 51-604.16
EFFECTIVE: February 2011
Copyright 2011 Magnetrol International, Incorporated. All rights reserved. Printed in the USA. SUPERSEDES: July 2010
Tri-Clamp is a registered trademark of Ladish Co.